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This study focuses on products with high length-to-thickness ratios, where injection pressure struggles to propagate effectively to the far-gate regions, resulting in excessive pressure differentials across the mold cavity and ultimately compromising the product’s dimensional accuracy. The dimensional accuracy of these plastic parts is directly related to three factors: injection speed, screw position at the V/P switchover point, and holding pressure method. Through simulations and physical molding trials, this study proposes a least squares method to determine the optimal V/P switchover point. The method calculates the minimum Euclidean distance between the relative error points (width, thickness) of the far-gate region and the zero point. The results show that the optimal screw position for V/P switchover is 21.7 mm. At this position, the relative errors in width and thickness are reduced to 0.3% and 0.5%, respectively. Furthermore, a four-stage holding pressure method with gradient reduction is adopted. This reduces the pressure difference between near-gate and far-gate regions by 3.29 MPa. It also decreases dimensional variations in the near-gate region by 58.3% in width and 56.3% in thickness. These improvements significantly enhance the final product quality.

Precision injection molding method based on V/P switchover point optimization and pressure field balancing